Composite Fuel Lines with Locally Tailored Fibers
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Solution Overview
Problem
Metal fuel system components in aircraft are heavy, have inadequate weld strength, and require time-consuming electromagnetic interference (EMI) protection processes, while existing fluid line manufacturing methods lack precision in bend designs.
Innovation Solution
The development of composite fuel lines made from fiber-reinforced plastic with locally tailored laminated layers, using a braiding process and a volumetric chamber for consolidation, allowing for varying compaction pressures to meet local load requirements and eliminate EMI effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If metal components are used for fuel lines, then ease of fabrication is improved, but weight increases and weld strength becomes insufficient
Solution Approach 1:
The patent uses composite materials consisting of a polymer matrix reinforced with fibers (such as carbon fiber, glass fiber, or aramid fiber) to manufacture fuel lines. This composite construction provides both the fabrication advantages of metal and the weight reduction benefits, while also offering superior strength-to-weight ratio and eliminating weld requirements through compression fitting connections.
2Strength
If metal components are used for fuel lines, then structural strength is improved, but electromagnetic interference protection becomes necessary
Solution Approach 1:
The patent employs a non-conductive polymer matrix material that inherently provides electromagnetic interference protection without requiring additional shielding treatments. The composite structure creates an electrically inert environment for the fuel, eliminating the need for time-consuming EME protection processes required by metal components while maintaining structural strength through fiber reinforcement.
3Ease of manufacture
If uniform fiber distribution is used in composite tubes, then manufacturing simplicity is improved, but local load requirements cannot be satisfied
Solution Approach 1:
The patent implements local quality by varying the fiber distribution, orientation, and density at different locations along the tube and in different radial directions. This allows the composite structure to be tailored to satisfy specific local load requirements, such as increased fiber concentration in high-stress bend areas, while maintaining manufacturing feasibility through controlled deposition processes.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution results in lightweight, easily manufactured fuel lines that resist higher temperatures and loads, eliminate the need for EMI protection, and achieve precise bend designs, reducing production costs and weight.
Implementation Method 1
A plurality of valves respectively in communication with the internal compartments are adapted be coupled with a source of pressure for applying different levels of compaction pressure respectively to the sections of the composite laminate tube
Implementation Method 2
Substantially vacuum tight seals separate the internal compartments from each other
Data Source
AI summary
A fluid line adapted to contain a pressurized fluid imposing loads on the line that vary along its length comprises a tube formed of a fiber reinforced plastic, wherein the fibers are locally tailored along the length of the tube to meet local load requirements. The tube is consolidated within a volumetric chamber having separate, individually controlled chamber compartments for respectively consolidating different segments of the tube.